AIRCRAFT CONTROL CABLE AIRCRAFT CONTROL CABLE INTRODUCTION I [ # Cables are the most widely used linkage in primary flight control systems. # Cable-type linkage is also used in engine controls, emergency extension system for the landing gear, and various other systems throughout the aircraft. #=— Cable-type linkage has several advantages over the other types. 1) It is strong and light in weight, 2) its flexibility makes it easy to route through the aircraft. 3) An aircraft cable has a high mechanical efficiency and can be set up without backlash, which is very important for precise control. # Cable linkage also has some disadvantages. 1) Tension must be adjusted frequently due to stretching and temperature changes. Cable Construction: # Aircraft control cables are fabricated from galvanized carbon steel or corrosion resistant steel. “4 The basic component of a cable is a wire. The diameter of the wire determines the total diameter of the cable. # A number of wires are preformed into a helical or spiral shape and then formed into a strand. # These preformed strands are laid around a straight center strand to form a cable. # Cable designations are based on the number of strands and the number 18of wires in each strand. The most common aircraft cables are the 7X7 and 7X19. 7 strands, 7 wires to each strand 7X7 cable # The 7 X 7 cable consists of seven strands of seven wires each. Six of these strands are laid around the center strand. # (This is a cable of medium flexibility and is used for trim tab controls, engine controls, and indicator controls.) 7X 19 cable: 7 strands, 19 wires Diameter to each strand ~~ # The 7 X 19 cable is made up of seven strands of 19 wires each. # Six of these strands are laid around the center strand. # Aircraft control cables vary in diameter, ranging from 1/16 to 3/8. The diameter is measured as shown. (This -cable is extra flexible and is used in primary control systems and in other places where operation over pulleys is frequent.) Cable Fittings: Sas AN663. Double shank ball end terminal Qa ‘ANG64 Single shank ball end terminal # Cables may be equipped with several different types of fittings such as terminals, thimbles, bushings, and shackles. ## Terminal fittings are generally of the swaged type. # They are available in the threaded end, fork end, eye end, single-shank ball end, and double-shank ball end. 19# The threaded end, fork end, and eye end terminals are used to connect the cable to a turnbuckle, bell crank, or other linkage in the system. # The ball-end terminals are used for attaching cables to quadrants and special connections where space is limited. # The thimble, bushing, and shackle fittings may be used in place of some types of terminal fittings when facilities and supplies are limited and immediate replacement of the cable is necessary. Ss AN667_ Fork end cable terminal ANG8S Red end terminal AN668_ Eyo end cable terminal init oS AN666- Threaded cable terminal The thimble, bushing, and shackle fittings may be used in place of some types of terminal fittings when facilities and supplies are limited and immediate replacement of the cable is necessary. Inspection On control cabl At each regular inspection period, cables should be inspected for broken | wires by passing a cloth along their length and observing points where the | cloth snags. To thoroughly inspect the cable, move the surface control to their extreme travel limits. This will reveal the cable in pulley, fairlead, and drum areas. If the surface of the cable is corroded, relieve cable tension. Then carefully force thecable open by reverse twisting, and visually inspect the interior for corrosion. Corrosion on the interior strands of the cable indicates failure of the cable and requires replacement of the cable. If there is no internal corrosion, remove external corrosion with a coarse weave rag or fiber brush. (Ce Never use metallic wools or solvents to clean flexible cable. Metallic wools imbed dissimilar metal particles, which cause further corrosion. Solvents remove the internal cable lubricant, which also results in further corrosion. After thoroughly cleaning the flexible cable, apply corrosion-preventive compound. This compound preserves and lubricates the cable. Breakage of wires occurs most frequently where cables pass over pulleys and through fairleads. Typical breakage points are shown in figure 2-57. Control cables and wires should be replaced if worn, distorted, corroded, or otherwise damaged. Lockclad cable: tocrcuo a # Lockclad cable is used on some large aircraft for all long, straight runs. # it consists of the conventional flexible steel cable with aluminum tubing swaged to it to lock the cable inside the tubing. # Lockclad cable construction has certain advantages : a) Changes in tension due to temperature are lesS than with conventional cable. B) The amount of stretch at a given load is lesS than with conventional cable. 2# Lockclad cables should be replaced when the covering is worn through, exposing worn wire strands is broken; or shows worn spots which cause the cable to bump when passing over fairlead rollers. Control system components * Various components are used to transmit the Pilot's effort from the cockpit to the control surfaces or other system in the aircraft. * Some of control linkage system components are discussed in the following paragraph. Turn buckle: # A turnbuckle assembly is a mechanical screw device consisting of two threaded terminals and a threaded barrel. Figure illustrates a typical turnbuckle assembly. Length (Threads fhsh with ends of barrel) Swaged terminal Darel Pin eye Ficurr 6-23, Typical tumbuckle assembly. # Turnbuckles is fitted in the cable assembly for the purpose of making minor adjustments in cable length and for adjusting cable tension. One of the terminals has right-hand threads and the other has left- hand threads. The end of the barrel with the left-hand threads can usually be identified by a groove or knurl around that end of the barrel. When installing a turnbuckle in a control system, it is necessary to screw both of the terminals an equal number of turns into the barrel. * Itis also essential that all turnbuckle terminals be screwed into the barrel until not more than three threads are exposed on either side of the turnbuckle barrel. After a turnbuckle is properly adjusted, it must be safetied.Control Pulleys : Pulleys are used to guide cables and also to change the direction of cable movement. it « ¥ Pulley bearings are sealed, and need no lubrication other than the lubrication done at the factory. Brackets fastened to the structure of the aircraft support the pulleys. Cables passing over pulleys are kept in place by guards. The guards are close-fitting to prevent jamming or to prevent the cables from slipping off when they slacken due to temperature variations. AIR PRESSURE SEAL Pressure seals are installed where cables (or rods) move through pressure bulkheads. The seal grip tightly enough to prevent excess air pressure loss but not enough to hinder movement of the cable. Pressure seals should be inspected at regular intervals to determine that the retaining rings are in place. If a retaining ring comes off, it may slide along tht cable and cause jamming of a pulley. 23Bell crank: A bell crank is used to transmit force and permit a change in the direction of force. Fairlead * A fairlead may be made from a nonmetallic material, such as phenolic or a metallic material such as soft aluminum. ji “The fairlead completely encircles the cable where it passes through holes in bulkheads or other metal parts. Fairleads are used to guide the cable in a straight line through or between members of the aircraft. Fairleads should never deflect the alignment of a cable more than 3° from a straight line ide cables Control (push-pull) rods wee QS cv mes math, sae Tube, steel of Covi, Rad end, yo Nodenbtadel taney “awn ‘ ice 6:84 Popul tbe ane Contralredsare used as links in flight control systems to give a push-pull motion. They may be adjusted at one or both ends. * View A of figure shows the parts of a control rod. 24eit oi of a tube having threaded rod ends. An adjustable antifricti ‘ iction rod end, or rod end clevis, attaches at each sabe, ich end of the ¢ The rod end, or clevis, i , ;, permits attachment of the t i pitt je tube to flight system if 5: cs The check nut, when tightened, prevents th e rod end or clevis from loosening. Control cable tension check Aer To determine the amount of tension er is used. When properly maintained, a ension is determined by led to make an offset in the onacable,a tensiomet tensiometer is 98% accurate. Cable t measuring the amount of force need cable between two hardened steel blocks, called anvils. ble to form the offset. Ariser or plunger is pressed against the cal several. make a variety of tensiometers, each type designed Manufacturers cable sizes, and cable tensions. for different kinds of cable, ‘sample only [Esne) a nom | eS BB Sa irve | 00] 70 | eben [722 |e |2798 078 webelrs Tete) | a Bl wo | | 2 eo 2 Ble |2|2 me sl oo | | ar 2 o$ Qe s foe elas |e se - . ee One type of tensiometer is lace the cable to be illustrated in figure, With the trigger lowered, pl se the trigger (move it up). d under the two anvils. Then clo! teste A ..* Movement of the trigger pushes up the riser, which pushes the cable at right angles to the two clamping points under the anvils, The force that is required to do this is indicated by the dial pointer. As the sample chart beneath the illustration shows, different numbered risers are used with different size cables. Each riser has an identifying number and is easily inserted into the tensiometer. * In addition, each tensiometer has a calibration table which is used to convert the dial reading to pounds. (The calibration table is very similar to the sample chart shown below the illustration.) * The dial reading is converted to pounds of tension as follows. Using a No. 2 riser to measure the tension of a 5/32-in. diameter cable a reading of "30" is obtained. The actual tension (See calibration table) of the cable is 70 Ibs. Observing the chart, also notice that a No. 1 riser is used with 1/16.. 3/32-, and 1/8-in. cable. * Since the tensiometer is not designed for use in measuring 7/32- or 1/4-in. cable, no values are shown in the No. 3 riser column of the chart. * When taking a reading, it may be difficult to see the dial. Therefore, a pointer lock is present on the tensiometer. Push it in to lock the pointer. Lben remove the tensiometer from the cable and observe the reading. After observing the reading, dull the lock out and the painter will return to zero. Temperature Chart * Cable rigging tension charts (figure 2-65) are graphic tools used to compensate for temperature variations. * They are used when establishing cable tensions in flight control systems, landing gear systems, or any other cable-operated systems. * To use the chart, determine the size of the cable that is to be adjusted and the ambient air temperature. For example, assume that the cable size is 1/8-in. in diameter, that it is a 7 x 19 cable, and the ambient air temperature is 85" F. Follow the 85' F. line upward towhere it intersects the curve for 1/8-in. cable. Extend a horiz ontal line from the point of intersection to the right edge of the chart. establish on the cable. The tension for this example is 70 Ibs. Values include 10 percent structural deflection Design limit rg load 40 320 300 260 20 20 Cable sises 220 VA 7x19: 00) 3/16 7x19 be 169 sys 7x19 = vs Ta19, 10 9/32 TT. mad W16 7x7 = 65-00 -50-40 -30-20-10 0 10 20 30 40 $0 60 70 #0 G0 100110120130140 150 160 “Temperate in depres fahireit The value at this point indicates the tension (rigging load in pounds) to Rigging load in pounds